Hypodermic needle extraction and disposal system apparatus

ABSTRACT

A hypodermic needle extraction device for removing a hypodermic needle from a syringe having a syringe body and a luer, the device including at least one guide rod disposed with the device, a carriage assembly having a carriage slidably mounted on the guide rod, and a needle extraction assembly configured to grasp the needle such that the needle is separated from the syringe body as the syringe body and needle are urged apart. This Abstract is presented to meet requirements of 37 C.F.R. §1.72(b) only. This Abstract is not intended to identify key elements of the apparatus and methods disclosed herein or to delineate the scope thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/470,853 filed on May 22, 2009 entitled HYPODERMIC NEEDLE EXTRCTIONAND DISPOSAL SYSTEM AND DEVICE, and a continuation of U.S. patentapplication Ser. No. 12/470,866 filed on May 22, 2009 entitledHYPODERMIC NEEDLE EXTRCTION AND DISPOSAL SYSTEM AND DEVICE, that, inturn, are continuations of U.S. utility patent application Ser. No.10/945,197 filed Sep. 20, 2004 entitled HYPODERMIC NEEDLE EXTRCTION ANDDISPOSAL SYSTEM AND DEVICE, that claims priority to U.S. provisionalpatent application 60/503,909 filed on Sep. 18, 2003 entitled HYPODERMICNEEDLE EXTRACTION DISPOSAL DEVICE AND SYSTEM and U.S. provisional patentapplication 60/506,256 filed on Sep. 26, 2003 entitled HYPODERMIC NEEDLEEXTRACTION DISPOSAL DEVICE AND SYSTEM. U.S. patent application Ser. No.12/470,853, U.S. patent application Ser. No. 12/470,866, U.S. utilitypatent application Ser. No. 10/945,197, U.S. provisional patentapplication 60/503,909, and U.S. provisional patent application60/506,256 are hereby incorporated by reference herein in theirentirety.

BACKGROUND OF THE INVENTION

1. Technical Field

The present disclosure relates generally to methods and devices for usein processing syringes such as those used in the medical industry. Morespecifically, the present disclosure relates to hypodermic needleextraction devices that render used syringes safe for disposal and/orrecycling.

2. Related Art

The medical industry has experienced an exponential increase in theincidence of accidental needle punctures experienced during the disposaland/or storage of used syringes. Accidental needle punctures pose apotentially deadly and serious problem to medical care providers, aswell as to individuals handling used syringes. Accidental “needlesticks” may also be costly to diagnose and/or treat. It is estimatedthat the expense to identify and treat a medical condition acquired as aresult of a “needle stick” is within the range of between two thousandand five hundred thousand dollars ($2,000.00 and $500,000.00).

Medical industry insurers have been desperate to identify ways toeliminate and/or minimize the risk of inadvertent “needle sticks” tomedical service providers and/or individuals involved in the handlingand disposal of used syringes. In addition, self-insuring medicalfacilities are especially interested in a cost effective solution toeliminate the growing “needle stick” problem.

Currently, used syringes are collected and/or held in a heavy walled bagknown in the industry as a sharp bag or box. Currently, a caregiver isrequired to deposit a used syringe and needle into an appropriate sharpbag or box. A number of disadvantages arise through the use of a sharpbag or box by a caregiver. Initially, a caregiver is required toexercise extreme caution to not acquire an inadvertent “needle stick”during the placement of a used syringe into a sharp bag. In addition,used needles protruding from a sharp bag pose a serious risk to acaregiver as the sharp bag becomes filled to capacity. Persons handlinga sharp bag filled with used needles must also be extremely careful tonot obtain an accidental “needle stick,” especially when emptying thesyringes or transporting the sharp bag. Frequently, sharp bags are notautomatically sealed, thereby further increasing the potential ofinadvertent “needle sticks” to individuals. As well, syringes aretypically not sterilized prior to transportation, storage, and/ordisposal.

Additional risks are also present with respect to the handling of usedsyringes outside of a medical facility environment. Home health care,such as that practiced by many individuals having diabetes, may requirethe disposal of a number of used syringes each day. Additionally, usedsyringes may be disposed of without destruction, which, in turn, mayfurther expose the public to the danger of improper reuse and/or “needlesticks.”

The considerations referenced above are just a few of the major problemsassociated with the handling and disposal of used syringes. Theconsiderations identified above also show a critical need for a devicewhich safely and effectively renders used syringes harmless andnon-reusable, thereby facilitating disposal and/or recycling.

Therefore, there is a need for improved methods and devices forrendering used syringes safe for disposal and/or recycling that addressthese and other shortcomings of the prior art.

BRIEF SUMMARY OF THE INVENTION

Briefly described, the present disclosure relates to a hypodermic needleextraction and disposal device for removing a hypodermic needle from asyringe having a syringe body and a luer. The device includes at leastone guide rod disposed within said device, a carriage assembly having acarriage slidably mounted on the guide rod, and a needle extractionassembly configured to grasp the needle such that the needle isseparated from the syringe body as the syringe body and needle are urgedapart.

A further embodiment of the present disclosure relates to a hypodermicneedle extraction and disposal device for removing a hypodermic needlefrom a syringe having a syringe body and a luer. The device includes ahousing, a carriage assembly including a carriage disposed within thehousing, a motor configured to move the carriage relative to thehousing, and a needle extraction assembly configured to grasp the needlesuch that the needle separated from the syringe body as the needle andthe syringe body are urged apart. The device further includes a binincluding a bin door, the bin being slidably received within the housingand configured to receive the needle after separation from the syringebody. The bin door is configured to move to a shut position as the binis removed from the housing and move to an open position as the bin isinserted into the housing.

Other objects, features and advantages of the present disclosure willbecome apparent upon reading the following specification, taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the hypodermic needle extraction and disposal device canbe better understood with reference to the following drawings. Thecomponents in the drawings are not necessarily to scale, emphasisinstead being placed upon clearly illustrating the principles of thepresent hypodermic needle extraction and disposal device. Moreover, inthe drawings, like reference numerals designate corresponding partsthroughout the several views.

FIG. 1 is a perspective view of an embodiment of an embodiment ofinternal components of a hypodermic needle extraction and disposaldevice;

FIG. 2 is a partial perspective view of an embodiment of internalcomponents of the hypodermic needle extraction and disposal device shownin FIG. 1;

FIG. 3 is a partial perspective view of an embodiment of internalcomponents of the hypodermic needle extraction and disposal device shownin FIG. 1;

FIG. 4 is a partial perspective view of an embodiment of internalcomponents of the hypodermic needle extraction and disposal device shownin FIG. 1;

FIG. 5 is a partial perspective view of an embodiment of internalcomponents of the hypodermic needle extraction and disposal device shownin FIG. 1, during operation;

FIG. 6 is a detailed cross sectional end view of the body clamp plungersand syringe, shown in FIG. 5;

FIG. 7 is a front detailed view of the heater elements and syringe shownin FIG. 5;

FIG. 8 is a front detailed view of the heater elements engaged to theluer of the syringe;

FIG. 9 is a partial perspective view of the hypodermic needle extractionand disposal device shown in FIG. 1;

FIGS. 10A and 10B are partial perspective views of a bin cover and bindoor, respectively, as shown in FIG. 9;

FIG. 11 is a perspective view of an embodiment of a hypodermic needleextraction and disposal device;

FIG. 12 is a partial perspective view of an embodiment of the internalcomponents of the needle extraction and disposal device shown in FIG.11;

FIG. 13 is a perspective view of a center chassis of the hypodermicneedle extraction and disposal device shown in FIG. 12;

FIG. 14 is a perspective view of an embodiment of a hypodermic needleextraction and disposal device;

FIG. 15 is a partial perspective view of an embodiment of the internalcomponents of the hypodermic needle extraction and disposal device shownin FIG. 14.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the description of thehypodermic needle extraction and disposal device as illustrated in thedrawings. While the hypodermic needle extraction and disposal devicewill be described in connection with these drawings, there is no intentto limit it to the embodiment or embodiments disclosed therein. On thecontrary, the intent is to cover all alternatives, modifications, andequivalents included within the spirit and scope of the hypodermicneedle extraction device as defined by the appended claims.

In particular, FIG. 1 illustrates an embodiment of a hypodermic needleextraction and disposal device 100 according to the present disclosure.The hypodermic needle extraction and disposal device 100 is used forprocessing a syringe 12 (FIG. 5) which generally includes a needle 14, abody 16, a luer 18, and a plunger (not shown). The hypodermic needleextraction and disposal device 100 is enclosed within a housing 102, thehousing 102 preferably being formed of a lightweight, yet sturdy plasticmaterial.

As shown, the housing 102 includes a number of indicator lamps 106, suchas light-emitting diodes (LEDs). Preferably, a ready indicator lamp 106indicates the availability of the hypodermic needle extraction anddisposal device 100 for use in processing a used syringe 12. A bin fullindicator lamp 106 indicates the necessity for replacement of either theneedle bin and/or the syringe body bin 160 (FIG. 9). The bin fullindicator lamp 106 signals when either the needle bin or the syringebody bin 160 have become full following the processing of a plurality ofused syringes 12. As well, the housing 102 may also include a powerswitch and a power input jack (not shown) which may be utilized tosupply power to the hypodermic needle extraction and disposal device100.

As shown, the exterior of the housing 102 also includes a syringe guidecutout 103 which orientates a syringe 12 into position for introductioninto the hypodermic needle extraction and disposal device 100. Thesyringe guide cutout 103 provides a self-contained area for theplacement of a syringe 12 prior to processing. The syringe guide cutout103 is proximate to a syringe receiving door 104 that provides accessinto the hypodermic needle extraction and disposal device 100. Thesyringe guide cutout 103 can also be integral to a hopper mechanism (notshown) which is utilized to store a number of used syringes 12 forautomatic processing by the hypodermic needle extraction and disposaldevice 100. The hopper mechanism can function on the same principles asa clip for ammunition, a gravity drop via a channel, a standard shapedhopper, or a conveyor.

Preferably, the syringe receiving door 104 is operated by an electroniccontrol system, as disclosed in U.S. Pat. No. 5,741,230, to Miller,which is incorporated herein by reference in its entirety. The syringereceiving door 104 is opened via a pinion gear 101 a engaging a rack103, thereby permitting a used syringe 12 to enter the hypodermic needleextraction and disposal device 100 for processing.

As shown in FIG. 2, the syringe receiving door 104 is a platform that isretracted or slid laterally, thereby allowing the syringe to dropvertically into the hypodermic needle extraction and disposal device100. However, alternate embodiments of the hypodermic needle extractionand disposal device 100 can include a platform having a hinge thatpermits the platform to rotate downwardly into the interior of thehousing 102. A receiving door opto-sensor (not shown) is adjacent thesyringe receiving door 104. The receiving door opto-sensor senses thepresence of a syringe 12 being placed proximate to the syringe receivingdoor 104. If no other processing functions are occurring within thehypodermic needle extraction and disposal device 100, the receiving dooropto-sensor electrically signals the electronic control system to openthe syringe receiving door 104. Preferably, a small motor 101 is used todrive a pinion gear 101 a that is operatively connected to a rack 103located on the syringe door 104. As the syringe receiving door 104 opensthe syringe 12 drops into the housing 102 and processing operations areinitiated. The syringe receiving door 104 then returns to the closedposition.

The receiving door opto-sensor is a proximity device which detects thepresence of an object within a certain distance. The receiving dooropto-sensor does not physically make contact with a syringe 12. As well,once the receiving door opto-sensor indicates the presence of a syringe12 proximate the syringe receiving door 104, the electronic controlsystem permits the opening of the syringe receiving door 104 only atsuch time as the hypodermic needle extraction and disposal device 100has completed processing of the previous syringe 12 and is ready toinitiate further processing procedures.

Referring now to FIGS. 3-5, a carriage assembly transports the usedsyringe 12, as received through the syringe receiving door 104, duringprocessing by the hypodermic needle extraction and disposal device 100.Preferably, the carriage assembly is formed of a carriage 100, acarriage gear rack 122, and a carriage motor 124 having a pinion gear126.

As shown, the carriage 110 is mounted on a plurality of guide rods 115.Preferably, the guide rods 115 are constructed of stainless steel andallow the carriage 110 to be urged along the guide rods 115 as necessaryduring processing operations. The carriage 110, when positioned in theat-rest location, is below the syringe receiving door 104 and above areceiving platform formed by the receiving doors 130. Each receivingdoor 130 is mounted within the housing on a shaft (not shown) such thatthe receiving doors 130 can freely rotate, as discussed hereafter. Whenthe carriage 110 is in the at-rest position, both receiving doors 130are horizontally positioned, thereby forming the platform onto which thesyringe 12 drops once the syringe receiving door 104 is opened.

Preferably, a carriage opto-sensor (not shown) is positioned adjacentthe carriage 110 when the carriage 110 is in the at-rest location underthe syringe receiving door 104. The carriage opto-sensor identifies thepresence of a syringe 12 on the receiving platform formed by thereceiving doors 130 and signals the electronic control system toinitiate processing operations.

Preferably, a pair of body clamp plungers 112 is used to both raise thesyringe 12 off the receiving platform and to securely clamp the syringebody 16 during processing. The body clamp plungers 112 are oppositelydisposed and configured for the centering of the needle 14 in a desiredx-y coordinate (FIG. 6), regardless of the varying diameters of thesyringe bodies 16. Preferably, each body clamp plunger 112 has a squarecross section and is slidably mounted in a square channel on thecarriage 110. A pair of barrel clamp motors 118, each barrel clamp motor118 having pinion gear 117, is used to urge the body clamp plungers 112inwardly so that they engage the syringe 12. Each pinion gear 117engages a gear rack 116 formed on the respective body clamp plunger 112.Each gear rack 116 can be either integral to or affixed to the bodyclamp plunger 112. As well, the square channels may be either affixed toor integral to the carriage 110.

The pair of barrel clamp motors 118 move the barrel clamp heads 114inwardly for engagement of the syringe 12. The pair of barrel clampheads 114 are preferably formed in an opposing V-shaped configuration,thereby facilitating the application of an identical clamping pressureto the body 16 of a syringe 12, regardless of the diameter of the body16. The current or voltage required for clamping of the syringe body 16by the barrel clamp motors 118 then sensed and/or analyzed by theelectronic control system. Upon sensing of a pre-established voltage orcurrent threshold, the electronic control system signals the barrelclamp motors 118 to maintain the barrel clamp plungers 112 in thedesired position.

The opposing V-shaped clamps of the barrel clamp heads 114 engage thesyringe body 16 below the center line to facilitate the elevation andlifting of the syringe 12 for centering in the desired x- andy-coordinate (FIG. 6). The opposing V-shaped barrel clamp heads 114obtain an identical x- and y-coordinate for the needle 14 regardless ofthe size of the needle 14 or the diameter dimension for the syringe body16. The utilization of the square body clamp plungers 112 within thesquare plunger channels 80 maintains the orientation of the barrel clampheads 114, thereby maintaining vertical, horizontal, and rotationalintegrity during operation of the hypodermic needle extraction anddisposal device 100. As well, utilization of the square body clampplungers 112 helps prevent the rotation of the barrel clamp heads 114out of position.

Preferably, the carriage opto-sensor preferably signals the electroniccontrol system to initiate the grasping of a syringe 12 from thereceiving platform. The electronic control system then signals thebarrel clamp motors 118 to move the body clamp plungers 112 inwardly sothat the barrel clamp heads 114 engage the body 16 of the syringe 12.The engagement between the barrel clamp heads 114 and the syringe body16 elevates the syringe body 16, positioning the needle 14 in thedesired x- and y-coordinate. As the inward positioning of the body clampplungers 112 continues, increased pressure is exerted upon the body 16.As such, the barrel clamp motors 118 then signal the electronic controlsystem of a desirability of more power. Once a certain power demandthreshold has been encountered, the electronic control system signalsthe barrel clamp motors 118 to maintain the desired position for theremainder of the sterilization and processing procedures of the usedsyringe 12.

The signal from the carriage stop opto-sensor communicates to theelectronic control system that the needle 14 has been positioned asdesired, upon which the electronic control system signals the heaterassembly to engage the luer 18 of the syringe 12. Preferably, the heaterassembly includes a pair of heater motors 140, square plungers 141positioned within square plunger channels, heater elements 142, andthermalcouples (not shown). The advantages as described for the squareplungers and square plunger of the body clamp plungers 112 are equallyapplicable to the heater assembly described herein.

Preferably, the carriage 110 is moved forwardly and rearwardly along theguide rods 115 by the engagement of the carriage motor 124 which rotatesthe pinion gear 126 along the carriage gear rack 122. The engagement ofthe carriage motor 124 occurs through the receipt of signals from theelectronic control system. As shown in FIGS. 4 and 5, the electroniccontrol system signals the carriage motor 124 to rotate in acounter-clockwise direction as viewed from above. As such, the carriage110 is forwardly positioned such that the syringe 12 is proximate to theheater elements 142, which can be ceramic heater heads. It should benoted that if the presence of a luer 18 on the carriage 110 is notidentified by the transfer carriage opto-sensor, a signal will begenerated to the electronic control system which returns the carriage110 to the at-rest position.

As seen in FIGS. 4 and 5, as the carriage 110 and syringe 12 are urgedforwardly along the guide rails 115, a tab or wing surface 134 on eachof the receiving doors 130 slides along a portion of the carriage 110.Preferably, as each wing surface 134 slides along the sloped portion, orbullnose 111, of the carriage 110, each receiving door 130 rotatesdownwardly such that there is no longer a platform formed beneath thecarriage 110. This allows access to the bin 160 positioned thereunder,as is later discussed.

Preferably, the forward motion of the carriage 110 is limited by acarriage stop opto-sensor (not shown) which is positioned adjacent theforward or leading edge of the heater assembly. The carriage stopopto-sensor is preferably adapted to sense and signal the presence ofthe luer 18 of the syringe 12 in a desired forward location. Thecarriage stop opto-sensor initiates a signal to the electronic controlsystem upon sensing of the leading edge of the luer 18 of the syringe12. The carriage stop opto-sensor enables the processing of syringes 12having varying lengths by terminating the forward motion of all syringes12 at a standard forward position. At this standard position, the luer18 is presented in proximity to the heater elements 142 that are locatedon the square plungers 141. The carriage stop opto-sensor is a proximitydevice which detects the presence of a non-conductive material within acertain distance, such as a syringe 12.

Preferably, heater motors 140 engage the square plungers 141 through theutilization of screw shafts and cert nuts. The front surfaces of thesquare plungers 141 accommodate the heater elements 142. Upon thepositioning of the needle 14 in the desired position, the electroniccontrol system signals the heater motors 140 to urge the square plungers141 inwardly such that the heater elements 142 contact the luer 18 ofthe syringe 12. Preferably, the electronic control system initiates theapplication of power to the heater elements 142 when the transfercarriage opto-sensor signals the electronic control system of thepresence of a syringe 12 on the receiving platform. As such, the heaterelements 142 have already obtained a temperature of approximately 130°Celsius by the time the heater motors 140 receive a signal to positionthe heater elements 142 into contact with the luer 18. The heater motors140 urge the heater elements 142 inwardly until such time as an increasein the current/voltage is requested, indicating contact with the luer 18(FIG. 7). The electronic control system signals the heater motors 142 toterminate the inward positioning of the heater elements 142 whilecontinuing engagement of the heater elements 142 with the luer 18 of thesyringe 12. The heater elements 142 then are utilized to soften the luer18 to facilitate the extraction of the needle 14 from the syringe 12 bythe needle extraction assembly. The heater elements 142 can include anangular contact surface which is adapted to flushly engage the luer 18of the syringe 12 over the entire length of the respective heaterelement 142.

When the heater elements 142 have acquired a temperature ofapproximately 130° Celsius, the thermalcouples will signal theelectronic control system to terminate/regulate power for the provisionof further heat to the heater elements 142. An additional temperatureincrease to the heater elements 142 is not desired in order to reducethe risk that the heater elements 142 will melt the plastic luer 18 ofthe syringe 12. Preferably, heater elements 142 soften the luer 18 forextraction of the needle 14, however, they do not fully melt the luer18. Sufficient power is provided as regulated by the thermalcouples toretain the heater elements 142 at a temperature of approximately 130°Celsius during the softening of the luer 18.

Simultaneous to the engagement of the heater assembly for heating of theluer 18, the electronic control system signals the needle extractionassembly to grasp the needle 14. Preferably, the needle extractionassembly includes a needle extraction platform 150, a platform motor152, a pair of needle tip clamp motors 154, square plungers 155, squareplunger channels, and a pair of needle tip grippers 156, each preferablya carbide gripper.

The needle extraction platform 150 is slidably mounted to a plurality ofguide rods 115 which allow for the linear motion of the needleextraction platform 150. Preferably, the needle extraction platform ismounted to the same set of guide rods 115 upon which the carriage 110 ismounted. The forward positioning of the needle extraction platform 150is preferably limited by the electronic control system via theprogramming of a distance for forward rotation of the needle extractionshaft 150. It should also be noted that the inward or forwardpositioning of the needle extraction platform 150 is a known distancewhich may be pre-programmed as a threshold within the microprocessor ofthe electronic control system.

The at-rest position for the needle extraction assembly is adjacent theheater assembly. In order to engage the needle 14, the electroniccontrol system signals the needle tip clamp motors 154 to rotate thescrew shafts for inward positioning of the square plungers 155 withinthe square plunger channels. The needle tip grippers 156, having theknurled carbide grippers, are affixed to the square plungers 155. Theoperations, interactions, and advantages as earlier described for thesquare plungers 141 and square plunger channels of the heater assemblysimilarly apply to the needle extraction assembly.

The needle tip clamp motors 152 apply power for the grasping of theneedle 14 by the needle tip grippers 156. As the pressure increasesbetween the needle tip grippers 156 and the needle 14, a signal iscommunicated to the electronic control system for an increased level ofvoltage or current to be utilized by the needle tip clamp motors 154.The electronic control system signals the needle tip clamp motors 154 toterminate further inward rotation of the screw shafts therebymaintaining the needle 14 securely between the needle tip grippers 156.Simultaneous with the signal from the electronic control system toterminate further pressure upon the needle 14 by the needle tip grippers156, the electronic control system signals the platform motor 152 toexert a retracting force upon the needle extraction platform 150. Theneedle extraction motor 152 then moves the needle extraction platform150 rearwardly away from the luer 18. The needle extraction platform 150is moved rearwardly via the rotational engagement of the needleextraction shaft 151 and a threaded nut (not shown), that is affixed to,or integral with, the needle extraction platform 150.

As the luer 18 becomes softened following exposure to heat from theheater elements 142, the engagement between the needle 14 and the luer18 becomes weaker. The luer 18 eventually becomes sufficiently soft topermit the extraction of the needle 14 from the luer 18. During thissequence, the platform motor 152 is exerting a retraction pressure uponthe needle extraction platform 150. The platform motor 152 waits for areduction in the current requirement for extraction of the needle 14,which is indicative of the softening of the luer 18 and the release ofthe needle 14 from the luer 18. The electronic control system thensenses the imminent extraction of the needle 14 from the syringe 12,whereupon the electronic control system increase power to the needleextraction motor 152. As such, the needle tip grippers 156 areretracted, thereby causing separation of the needle 14 from the luer 18.The extracting pressure exerted by the needle extraction motor 152provides a tugging force upon the needle 14 with respect to the syringe12. In one embodiment the tugging force upon the needle 14 can beconstant. The level of force exerted by the needle extraction motor 152is sufficient to sense the softening of the luer 18 and the slippage andretraction of the needle 14 from the luer 18.

The extraction of the needle 14 from the syringe 12 and the interactionbetween the carriage, body clamp plungers, heater assembly, and needleextraction assembly is preferably based upon an event sequence asopposed to a timing sequence. Therefore, the interrelationship is notaffected by the diameter dimensions for the syringe body 16 or theneedle 14. The electronic control system operates the platform motor 152and/or the needle tip clamp motors 154 based upon the analysis of thevoltage/current requirements for exertion of a desired amount ofpressure, whereupon the electronic control system will signal therespective platform motor 152 or needle tip clamp motors 154 to hold anacquired position.

Simultaneously with the needle 14 separating from the luer 18, theelectronic control system signals the heater motors 140 to pinch andcollapse the softened luer 18 by the heater elements 142, therebysealing of the internal cavity of the syringe body 16 (FIG. 8). Theheater motors 140 continue to exert compression pressure upon the luer18 until such time as a threshold is reached, upon which the electroniccontrol system signals the heater motors 140 to retract to an at-restposition. As well, the needle extraction platform 150 is furtherretracted rearwardly 170 for engagement of the needle 14 to the needletip contactor assembly (not shown).

Following the sealing of the syringe cavity, the heater elements 142 areretracted to their at-rest position and the electrical control systemsignals the body clamp motors 118 to retract the body clamp plungers 112to their start position, thereby permitting the syringe body 16 to dropbetween the open receiving doors 130 and into the syringe body bin 160(FIG. 9). The compression and sealing of the luer 18 by the heaterelements 142 occurs upon the extraction of the needle 14 from theplastic luer 18 as the base of the needle 14 clears the tip of theplastic luer 18. Compression of the luer 18 upon the separation of theneedle 14 from the syringe luer 18 helps prevent contamination orcontaminated substance from escaping the syringe 12.

Following the separation of the needle 14 from the luer 18, the needle14 is sterilized through the establishment of an electrical contact andsubsequent heating with the needle tip contactor 157. The needle tipcontactor 157 is preferably spring mounted (not shown). The tipcontactor 157 includes a conical shaped receiving end which is adaptedto engage the tip of a needle 14. The tip contactor 157 is in electricalcommunication with the needle tip grippers 156.

Preferably, the tip contactor 157 is a spring and formed of a onequarter inch brass diameter shaft having a conical shaped receiving end.A needle 14 engaging the receiving end may thereby be centered forsterilization and processing. Upon engagement of the needle 14 with thetip contactor 157, an electrical connection is established and theelectronic control system applies power across the needle 14 such thatthe needle 14 is used as an element. Preferably, the electronic controlsystem places approximately twelve to twenty volts, corresponding totwelve to fifteen amps, across the needle 14 thereby sterilizing anychemistry or blood which may be present upon the needle 14. The conicalshaped receiving end, upon the heating of the needle 14, deforms thepoint of the needle 14 into a non-reusable condition. The needle tipgrippers 156 grasp the needle 14 proximate to the luer 18 in order tomaximize the distance between the tip of the needle 14 and the needletip grippers 156.

The electronic control system then terminates the application of energyacross the needle 14 whereupon the needle extraction motor 152 urges theneedle extraction platform 150 forwardly for return to the at-restposition. The needle 14 is thereby separated from the conical receivingend. The electronic control system then signals the needle tip clampmotors 154 to retract, separating the needle tip grippers 156 from theneedle 14, thereby permitting the needle 14 to drop into the needle bin130 (FIG. 3). All the elements of the hypodermic needle extraction anddisposal device 100 are then positioned for processing of another usedsyringe 12.

Preferably, the dropped syringe body 16 is received in the syringe bodybin 160, as shown in FIG. 9. Similarly, after the needle 14 has beenremoved and sterilized, the needle 14 is allowed to drop into the needlebin (not shown). Preferably, the needle bin 130 and the syringe body bin160 are both contained in a single sliding drawer 108. As shown, eachbin 160 includes a sliding bin door 166 that functions automatically asthe drawer 108 is both pushed into and pulled out of the housing 102.

As shown in FIG. 10A, a top view of an exemplary sliding bin door 166and bin cover 168, an actuator tab 167 extends upwardly from the slidingdoor 166 and into the bin cover 168. Preferably, the drawer is insertedinto the housing 102 with the bin door 166 in an open position. As thedrawer 108 is removed from the housing 102, the actuator tab 167 isengaged by angled rails or a slot (not shown) on the underside portionof the housing 102, thereby closing the sliding door 166. As shown inFIG. 10B, a bottom perspective view of the bin cover 168 and slidingdoor 166, the bin door 166 travels in channels 169 formed on theunderside of the bin cover 168. A pair of self-expanding barbs 165 helpslock the sliding door 166 in the closed position after the drawer 108has been removed from the housing 102. Note, various size drawers andbins may be used depending on the size and/or quantity of the syringesto be processed. As well, bin size selection may depend on whether theunit is used on a countertop, a floor stand, a nurse's cart, is wallmounted, or used by paramedics in the field.

An alternate embodiment of a hypodermic needle extraction and disposaldevice 200 is shown in FIGS. 11-13. As shown, the hypodermic needleextraction and disposal device 200 includes a housing 202 including aneedle orifice 204 and a drawer 208 (FIG. 13) slidably received therein.The hypodermic needle extraction and disposal device 200 operatesautomatically upon insertion of a syringe 12 into the needle orifice204, either by use of a mechanical switch or by use of opto electronics.Preferably, a wheel 209 is rotatably mounted to the housing 202, thewheel 209 including a plurality of orifice inserts 207 of differentsizes. The orifice inserts 207 assist the user in properly positioningthe syringe 12 relative to the hypodermic needle extraction and disposaldevice 200 for removal of the needle 14 therefrom. As well, a liquidcrystal display 206 is provided on the housing 202 to provideinformation to the operator. As previously noted, LEDs can also be usedto provide status information to the operator.

Preferably, a movable carriage 210 is slidably mounted within thehousing 202 on a plurality of guide rods 215 which are mounted inapertures 251 formed in the center chassis 250 (FIGS. 12 and 13). At thebeginning of each processing cycle, the carriage 210 is at the top ofits intended range of travel (the range being approximately one inch orless vertically). When the needle 14 of the syringe 12 is inserted intothe needle orifice 204, the hypodermic needle extraction and disposaldevice 200 is activated. Power is provided to the needle tip clamp motor254 which in turn urges the moveable needle tip gripper 257 toward theopposing stationary needle tip gripper 256, securing the needle 14therebetween. As the needle tip grippers 256, 257 squeeze the needle 14,the microprocessor senses greater load on the needle tip gripper motor254. At a predetermined current rise threshold programmed into themicroprocessor, the needle tip gripper motor 254 is turned off, leavingthe needle 14 secured between the needle tip grippers 256, 257.

After the needle 14 is held firmly by the needle tip grippers 256, 257,the carriage motors are activated, thereby urging the carriage 210downwardly away from the syringe body 16. The motion of the carriage 210relative to the syringe body 16 separates the needle 14 from the luer18. At a predetermined distance (preferably less than one inch), poweris secured to the carriage motors 252 as the needle 14 is now free ofthe luer 18. Preferably, a heater element (not shown) is locatedadjacent the needle orifice 204 such that when the needle is insertedtherein, the luer 18 of the syringe 12 is adjacent the heater element.The heater element softens the luer 18 thereby facilitating removal ofthe needle from the syringe 12.

The carriage motor 254 is turned on and reversed to separate themoveable needle tip gripper 257 from the stationary needle trip gripper256, thereby allowing the needle 14 to drop into the needle collectionbin 268 (FIG. 13). As a precaution to prevent needles 14 from stickingto one of the needle tip grippers 256, 257, a small loop 257 a isattached to the top of the moveable needle tip gripper 257. When theneedle 14 is first inserted into the hypodermic needle extraction anddisposal device 200, it passes through the loop 257 a. As the needle tipgrippers 256, 257 are opened, the needle 14 is forced off the face ofthe stationary needle tip gripper 256 as the needle 14 comes in contactwith the edge of the retreating loop 257 a. After the needle 14 has beendropped into the needle bin 268, the carriage motors 252 are turned onin reverse and the carriage 210 moves along the guide rods 215 back tothe upper position. As soon as the needle 14 has been removed from theluer 18, the user can remove the now needleless syringe body 16 from theneedle orifice 204 and place the syringe body 16 in the appropriatewaste container.

As best shown in FIG. 13, the drawer 208 and associated needle bin 260are slidably received in a center chassis 250. Similar to the previouslydiscussed embodiment, the needle bin 260 preferably includes a bin cover268 with an aperture formed therein and a bin door 266 having anactuator tab 267 extending upwardly therefrom. As the drawer 208 is slidinto and out of the center chassis 250, a slot (not shown) formed in thecenter chassis 250 causes the bin door to be automatically moved to anopen and a closed position, respectively. As well, a magnet is embeddedin the actuator tab 267 that interacts with a reed switch 258 positionedon the center chassis 250. The reed switch 258 is configured to detectthe location of the magnet, and subsequently the actuator tab 257. Assuch, the reed switch 258 can determine if the bin door 266 has moved tothe open position as the drawer 208 is inserted into the center chassis250. With the bin door 266 in the open position, the aperture in the bincover 268 is aligned with the needle aperture 256 formed in the centerchassis. As such, processed needles 14 can drop into the needle bin 260.If the bin door 266 remains in the closed position for some reason, thereed switch 258 provides a signal to the control system that preventsthe operation of the hypodermic needle extraction and disposal device200.

Preferably, a solenoid 270 is provided that is configured to lock theneedle bin 260 in place during operation of the hypodermic needleextraction and disposal device 200 by inserting an actuator (not shown)into a recess (not shown) formed in either the bin 260 or the drawer208. The solenoid 270 briefly retracts the actuator and allows thedrawer 208 to be removed once the needle bin 260 is full. Operation ofthe solenoid 270 is automatic and based on a count of how many needles14 have been processed. Preferably, the spring (not shown) positionedwithin the center chassis 250 forces the drawer 208 out of the centerchassis 250 when the solenoid 270 momentarily lifts an actuator (notshown) which normally engages a recess in the drawer 208, therebyholding the drawer 208 in position.

The hypodermic needle extraction and disposal device 200 operates whileplugged into a standard 110 V supply, or operates off a battery pack.Preferably, the batteries allow at least 80 to 100 cycles before needingto be recharged. The recharging system is built into the device. Noexternal charging system is necessary. Solar cells may also be mountedon the device to provide operating power and/or recharge the batterypack.

An alternate embodiment of a hypodermic needle extraction and disposaldevice 300 is shown in FIGS. 14 and 15. As shown, the hypodermic needleextraction and disposal device 300 includes a housing 302 including aneedle orifice 304 and a drawer 308 slidably received therein. Thehypodermic needle extraction and disposal device 200 operatesautomatically upon insertion of a syringe 12 into the needle orifice304, either by use of a mechanical switch or by use of opto electronics.

Preferably, the hypodermic needle extraction and disposal device 300operates automatically upon insertion of a syringe 12 into the needleorifice, either by use of a mechanical switch or opto electronics.Similar to various other embodiments, the hypodermic needle extractionand disposal device 300 includes a movable carriage 310 slidably mountedtherein. As shown, the carriage is mounted on a pair of guide rods 315.As best seen in FIG. 15, at the beginning of each processing cycle, thecarriage 310 is at the top of its intended range of travel (the rangebeing approximately one inch or less vertically). When the needle 14 ofthe syringe 12 is inserted into the needle orifice 304, the hypodermicneedle extraction and disposal device 300 is activated. Power isprovided to a needle tip clamp motor 354, which in turn urges themoveable needle tip gripper 357 toward the opposing stationary needletip gripper 356, securing the needle 14 therebetween. As the needle tipgrippers 356, 357 squeeze the needle 14, a microprocessor senses greaterload on the needle tip gripper motor 354. At a predetermined currentrise threshold programmed into the microprocessor, the needle tipgripper motor 354 is turned off, leaving the needle 14 secured betweenthe needle tip grippers 356, 357.

After the needle 14 is held firmly by the needle tip grippers 256, 257,carriage motors 352 are activated, thereby urging the carriage 310downwardly away from the syringe body 16. The motion of the carriage 310relative to the syringe body 16 separates the needle 14 from the luer18. At a predetermined distance (preferably less than one inch), poweris secured to the carriage motors 352 as the needle 14 is now free ofthe luer 18.

The carriage motor 254 is turned on and reversed to separate themoveable needle tip gripper 357 from the stationary needle trip gripper356, thereby allowing the needle 14 to drop into the drawer 308. Note, aneedle bin similar to those previously discussed can be placed in thedrawer 308 for the collection of needles 14.

Embodiments are envisioned where the hypodermic needle extraction anddisposal device 100 further includes a sterilization module (not shown).For example, after the needle 14 has been extracted from the luer 18,rather than being dropped directly into the syringe bin, the syringebody 16 can be dropped onto a sliding platform and flooded with UVlight. After a sufficient period of time has elapsed for the UV light todestroy bacteria, etc., the UV lamp is turned off. Once the UV light isturned off, the platform retracts to one side and the syringe body 16 isallowed to drop into the syringe collection bin. The sliding platformthen returns to its home position.

Other embodiments may include a syringe destruction device (not shown)to reduce the syringe bodies 16 to smaller pieces, therefore requiringless storage space in the syringe bin. For example, a syringedestruction device may include a moveable platform on which the syringeis positioned, and then pushed into a grinding or cutting area forreduction. The reduced pieces are then deposited into the syringecollection bin, thereby reducing the volume of storage space requiredper syringe.

Note, the sterilization unit and syringe destruction device can beeither integral parts of the disposal device 100 or can operateindependently as stand-alone systems. Preferably, hypodermic needleextraction and disposal device 100 microprocessor has firmware installedto allow for field upgrades of the hypodermic needle extraction anddisposal device 100 with the syringe destruction device in thesterilization unit. As such, the microprocessor can determine if one orboth of these devices are being used in conjunction with the disposalunit, and will vary all of the operation timing functions accordingly.When the syringe destruction device and sterilization unit are usedindependently as stand alone systems, they will have their ownmicroprocessor controller and related firmware and hardware.

Embodiments of the hypodermic needle extraction and disposal device 100are envisioned that have the ability to distinguish between standardsyringe/needle combinations and “engineered sharps” (safetysyringes—retractable or sheathed). By use of the optic systemsincorporated in the hypodermic needle extraction and disposal device100, the system can determine the type of syringe to be processed. Ifthe syringe is determined to be an engineered sharp, the processing isvaried to eliminate the needle extraction portion of the process and theengineered sharp is deposited into the syringe bin. As an alternative toplacing or depositing the safety syringe into the normal syringecollection bin, the hypodermic needle extraction and disposal device 100can be configured to allow for depositing the safety syringes into theirown separate syringe collection bin. In this configuration, the disposaldevice can distinguish between empty syringe barrels with no metal andsafety syringes with needles attached.

Various embodiments of the hypodermic needle extraction and disposaldevice 100 have the ability to communicate through wired and/or wirelessLANs (local area networks). As such, hypodermic needle extraction anddisposal device 100 can be poled from a central station as to eachdisposal unit's activity. As well, each hypodermic needle extraction anddisposal device 100 can be operated remotely and diagnostics routinescan be run to determine if the hypodermic needle extraction and disposaldevice 100 is functioning properly. A central control system (preferablyWindows® based) would allow personnel to communicate with a number ofhypodermic needle extraction and disposal device 100 in a system to viewactivity, status, etc. This allows for management of several hypodermicneedle extraction and disposal device 100 on one system.

Embodiments are also envisioned wherein syringe processing events may betime stamped, processed syringe sizes can be determined using look-uptables, the total number of syringes processed in a given amount of timeis recorded, and “instructions sets” regarding timing, motor currentsettings, etc., may be changed via the network connections, dependingupon the type syringe being processed.

Although preferred embodiments of the hypodermic needle extraction anddisposal device have been disclosed in detail herein, it will be obviousto those skilled in the art that variations and modifications of thedisclosed embodiments can be made without departing from the spirit andscope of the hypodermic needle extraction and disposal device as setforth in the following claims.

What is claimed is:
 1. An apparatus, comprising: a gripper adapted tograsp a needle; a syringe holder to secure a luer inserted into thesyringe holder by a user, the luer engaged with a syringe body and theneedle engaged with the luer, the syringe holder formed as a cylindricalstructure with a static wall, the syringe holder positions the needlefor grasping by the gripper; and, wherein with the needle grasped by thegripper the syringe holder and the gripper are adapted to move apartfrom one another linearly in a direction defined by a length of theneedle without relative rotation between the needle and the luer towithdraw the needle entirely from the luer.
 2. The apparatus as in claim1, wherein the luer is generally at ambient temperature as the needle iswithdrawn therefrom.
 3. The apparatus as in claim 1, further comprising:a heater element to apply heat to the luer to soften the luer in orderto facilitate withdrawal of the needle from the luer.
 4. The apparatusas in claim 3, wherein the heater element is heated to a temperature ofabout 130° C.
 5. The apparatus as in claim 1, further comprising: asensor adapted to detect insertion of the luer into the syringe holder.6. The apparatus as in claim 1, wherein the syringe holder is fixed andthe gripper is movable to move linearly apart from the syringe holder.7. The apparatus as in claim 1, wherein the gripper comprises: a grippermotor; a stationary needle gripper; a movable needle gripper operablyconnect to the gripper motor such that the gripper motor may move themovable needle gripper toward or away from the stationary needle gripperto grip the needle between the stationary needle gripper and the movableneedle gripper or release the needle from the stationary needle gripperand movable needle gripper, respectively; and a loop disposed about themovable needle gripper, the loop engages the needle to release theneedle from the stationary needle gripper as the movable needle grippermoves away from the stationary needle gripper.
 8. The apparatus as inclaim 1, further comprising: a housing, the syringe holder and thegripper being disposed about the housing; and, a drawer slidablyreceived within the housing and operative to receive the needle thereinfollowing withdrawal of the needle from the luer; and, a bin doordisposed about the drawer, the bin door adapted to move from an openposition to a locked closed position as the drawer is removed from thehousing.
 9. A method, comprising the steps of: securing a luer within asyringe holder by inserting the luer into the syringe holder, the luerbeing engaged with a syringe body and a needle being engaged with theluer, the syringe holder being formed as a cylindrical structure havinga static wall, the syringe holder positioning the needle for grasping bya gripper; grasping the needle by the gripper; and, withdrawing theneedle entirely from the luer by moving the syringe holder and thegripper assembly linearly apart from one another generally in adirection defined by a length of the needle without relative rotationbetween the needle and the luer following the step of grasping theneedle by the gripper assembly.
 10. The method as in claim 9, furthercomprising the step of: softening the luer by heating the luer using aheater element thereby facilitating the withdrawing of the needle fromthe luer.
 11. The method as in claim 10, wherein the heater element hasa temperature of approximately 130° C.
 12. The method as in claim 9,further comprising the step of: detecting insertion of the luer into thesyringe holder using a sensor thereupon initiating the grasping step andthe withdrawing step.
 13. The method as in claim 9, wherein thewithdrawing step is performed by moving the gripper linearly with thesyringe holder being fixed.
 14. The method as in claim 9, furthercomprising the step of: sterilizing the needle following the step ofwithdrawing the needle from the luer.
 15. The method as in claim 9,further comprising the step of: sterilizing the syringe body followingthe step of withdrawing the needle entirely from the luer.
 16. Themethod as in claim 9, further comprising the steps of: receiving theneedle within a drawer following the withdrawing step; and, positioninga bin door disposed about the drawer from an open position to a closedlocked position by removing the drawer from a housing with the needlecontained therein, the needle having been received within the drawer.